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Cardboard engineering

Structure, prototypes and cutter files

Designed and made in-house in Leicestershire
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Cardboard engineering

Worked out properly before it’s made

Good POS starts with the structure. We work out how it folds, how it holds the product and how it ships flat, then cut a real sample on our Kongsberg so you can test it.

Talk to us about a structure

We reply to every enquiry within 24 hours.

  • Designed and made in-house

    Every job is designed, printed, cut and finished on our own equipment in Wigston. No middleman.

  • Free quality-check samples

    See and handle a sample before the run goes ahead. It costs you nothing.

  • Prototypes in as little as 7 days

    A real unit you can load, walk round and judge before you sign off.

How we can help

Three ways to start

  • Consultation on new designs

    Draw on the full experience and expertise of our design team. We help you develop fresh ideas and new designs that suit your product and where it will sit.

  • New designs from your brief

    Already have a brief or a design? We work from what you have, refine the structure and bring your next display to life.

  • Reverse engineering

    Send us a physical example or a few images. We work from them to bring that inspiration into a display of your own.

What we make

What we engineer

The part most people never see: the folds, the locks and the load.

  • Cutter-file dieline for a Formatfifty9 display on a dark screen

    Structural design and cutter files

  • White sample prototypes

  • Hands folding a white flat-pack cardboard display up from flat on a workbench

    Flat-pack, quick-build designs

  • Shelves and trays that take the weight

  • White stepped cardboard sample with marked-up sketches and notes behind it

    Reworking an existing display

  • Copying a design from a sample or photos

  • Need something else on the floor?

    See FSDUs, Counter displays, Pallet units.

    Ask us →

Full service

How it works

  1. Brief

    Tell us what it is, where it sits, how many and when.

  2. Design

    We work it out with you, or work from your existing artwork.

  3. Prototype

    Rapid prototyping capabilities make the process seamless from idea, iteration and through to delivery.

  4. Production

    Once you sign it off, we print, cut and finish.

  5. Delivery

    Packed and sent anywhere in the UK, to one address or many.

Equipment

Same kit for your prototype and your rollout

Formatfifty9 was formed in 2025. We brought together a collective of passionate and experienced designers, production specialists and project managers with one mission: serve clients the best way we can.

  • In-house digital print

    Fujifilm Acuity Prime Hybrid UV, printing direct to board.

  • Screen print

    Up to 1600 × 1000mm when the job needs it, plus dye-sublimation.

  • Finishing

    Kongsberg X44 table to cut, crease, kiss-cut and mill, then finished on site.

  • Design

    Structure and artwork worked out in-house, in 2D and 3D.

  • Prototyping

    Real samples made on the same kit as your run.

Industries

Sectors we work in

  • Beauty and cosmetics
  • Food
  • Drinks
  • Confectionery
  • Health and wellbeing
  • Pet
  • Toys and games
  • Electronics
  • Home and garden
  • Stationery
  • Fashion and accessories
  • DIY and tools

Quick quote

Rapid turnaround on prototypes

In a hurry? Prototypes can be with you in as little as 7 days.

Enquire now

We reply to every enquiry within 24 hours.